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HRX-OM-H043 edition:Dec. 2003 Rev. D :Nov. 2008 st 1 Operation Manual Air-refrigerated Thermo cooler HRG001-A HRG002-A HRG005-A SMC Corporation Save This Manual Carefully for Use at Any Time © 2003 SMC CORPORATION All Rights Reserved To the Customers Thank you for purchasing our THERMO COOLER HRG Series (hereinafter called “This unit”). For safety and efficiency, be sure to read and understand this manual thoroughly before performing operation of this unit. z All warnings and precautions defined in this manual shall be observed. z This manual provides instructions for the installation and operation of this unit. Only those who have understanding of the operating procedure or have knowledge of the installation and operation of this unit are qualified to work with this unit. z The contents of this manual and related documents shall be neither regarded as a provision of the contract nor utilized to correct or modify the existing agreements, commitments and relations. z Copying, duplicating or transferring any part of or whole contents of this manual without SMC Corporation’s permission is strictly prohibited. z The Service Manual is supplied to provide additional information and troubleshooting of this unit. Only those who have full understanding of this unit are allowed to perform maintenance and repair of the unit with the use of the Service Manual. Note: The contents of this manual are subject to change without notice. Address : 4-14-1 Sotokanda, Chiyoda-ku, Tokyo 101-0021, Japan TEL : +81 3 5207 8249 FAX : +81 3 5298 5362 URL : http://www.smcworld.com HRX-OM-H043 Table of Contents Table of Contents 1. Safety Instructions ...................................................................... 1-1 1.1 1.2 BEFORE USING THIS UNIT ..............................................................................................1-1 DANGER, WARNING AND CAUTION .................................................................................1-2 1.2.1 Level of risk ......................................................................................................................... 1-2 1.2.2 Definitions of “Serious injury” and “Minor injury” ................................................................. 1-2 1.2.3 Symbols............................................................................................................................... 1-3 1.3 HAZARD WARNING LABEL .............................................................................................1-4 1.3.1 Classification of risks........................................................................................................... 1-4 1.3.2 Type of hazard warning labels ............................................................................................ 1-5 1.3.3 Location of hazard warning label ........................................................................................ 1-6 1.4 1.5 MODEL LABEL ...............................................................................................................1-6 DISPOSITION OF WASTE .................................................................................................1-7 1.5.1 Recovery of refrigerant and compressor oil ........................................................................ 1-7 1.5.2 Disposal of unit.................................................................................................................... 1-7 2. Descriptions of Components...................................................... 2-1 2.1 APPEARANCE OF UNIT ...................................................................................................2-1 2.1.1 HRG001-A / HRG002-A ...................................................................................................... 2-1 2.1.2 HRG005-A........................................................................................................................... 2-1 2.2 DESCRIPTIONS AND FUNCTIONS OF COMPONENTS...........................................................2-2 2.2.1 HRG001-A / HRG002-A ...................................................................................................... 2-2 2.2.2 HRG005-A........................................................................................................................... 2-3 2.2.3 Control panel ....................................................................................................................... 2-4 3. Transport and Installation........................................................... 3-1 3.1 3.2 TRANSPORT ..................................................................................................................3-1 INSTALLATION ................................................................................................................3-3 3.2.1 Installation Conditions ......................................................................................................... 3-3 3.2.2 Installation ........................................................................................................................... 3-4 3.2.3 Electrical wiring ................................................................................................................... 3-4 3.2.4 Piping................................................................................................................................... 3-7 3.2.5 Supply of circulating fluid..................................................................................................... 3-8 3.2.6 Reinstallation of unit ............................................................................................................ 3-9 4. Startup and Shutdown ................................................................ 4-1 4.1 PRE-CHECK ...................................................................................................................4-1 4.1.1 Installation condition............................................................................................................ 4-1 4.1.2 Connection of cable............................................................................................................. 4-1 4.1.3 Piping for circulating fluid .................................................................................................... 4-1 HRG001-A HRG002-A HRG005-A st 1 edition :Dec. 2003 Table of Contents-1 HRX-OM-H043 Table of Contents 4.1.4 4.2 Level indicator(for level in the tank) ................................................................................ 4-1 PREPARATION FOR STARTUP .......................................................................................... 4-2 4.2.1 Power supply ....................................................................................................................... 4-2 4.2.2 Setting of circulating fluid temperature ................................................................................ 4-2 4.2.3 Additional water supply........................................................................................................ 4-3 4.3 UNIT STARTUP AND SHUTDOWN ..................................................................................... 4-4 4.3.1 Starting the unit.................................................................................................................... 4-4 4.3.2 Stopping the unit .................................................................................................................. 4-4 4.4 CHECK AT STARTUP ....................................................................................................... 4-5 5. Error Message and Troubleshooting ......................................... 5-1 5.1 5.2 ERROR MESSAGE .......................................................................................................... 5-1 TROUBLESHOOTING....................................................................................................... 5-2 6. Unit Maintenance......................................................................... 6-1 6.1 6.2 CONTROL OF WATER QUALITY ........................................................................................ 6-1 INSPECTION AND CLEANING ........................................................................................... 6-2 6.2.1 Daily inspection.................................................................................................................... 6-3 6.2.2 Monthly inspection ............................................................................................................... 6-4 6.2.3 Biannual inspection.............................................................................................................. 6-5 6.3 6.4 STORAGE ...................................................................................................................... 6-6 CONSUMABLES ............................................................................................................. 6-6 7. Documents ................................................................................... 7-1 7.1 7.2 SPECIFICATIONS LIST ..................................................................................................... 7-1 OUTLINE DIMENSIONS .................................................................................................... 7-2 7.2.1 HRG001-A and HRG002-A.................................................................................................. 7-2 7.2.2 HRG005-A ........................................................................................................................... 7-2 7.3 ELECTRIC CIRCUIT DIAGRAM .......................................................................................... 7-3 7.3.1 HRG001-A and HRG002-A.................................................................................................. 7-3 7.3.2 HRG005-A ........................................................................................................................... 7-4 7.4 FLOW CHART ................................................................................................................. 7-5 7.4.1 HRG001-A and HRG002-A.................................................................................................. 7-5 7.4.2 HRG005-A ........................................................................................................................... 7-5 Table of Contents-2 HRG001-A HRG002-A HRG005-A st 1 edition : Dec. 2003 1 HRX-OM-H043 Safety Instructions 1. Safety Instructions Be sure to read and understand all the important precautions in this manual before operating the unit. 1.1 Before Using this Unit z This chapter describes the safety-related items that users should be aware of upon handling this unit. z This unit operates under high voltage and contains components that cause a rise in temperature and rotate. All personnel are required to read and understand the safety-related items in this manual before working with this unit. z This manual is not for comprehensive safety and hygiene education. Such a manual should be provided by a safety training manager. z All personnel who work on or around this unit are to have proper training and education on dangers specific to this unit and safety measures against potential hazards. z A safety manager is responsible for observing safety standards. Operators and service technicians have individual responsibilies for their safety during operation of this unit in his/her daily work. z Operators must individually take account of safety and assure a proper working area and working environment. z The relevant personnel must receive proper safety education before working on this unit to prevent dangers. Never conduct work training without giving proper consideration to safety. z Save this manual at a designated place for reference when necessary. HRG001-A HRG002-A HRG005-A st 1 edition :Dec. 2003 1.1 Before Using this Unit 1-1 HRX-OM-H043 1 Safety Instructions 1.2 Danger, Warning and Caution 1.2.1 Level of risk This unit is designed with the safety of workers and the prevention of system damage. This manual classifies the risks into the following three categories according to the level of the hazard: Danger, Warning, and Caution. Read the statements carefully and thoroughly understand them before operating this unit. DANGER, WARNING and CAUTION signs are in order according to severity (DANGER > WARNING > CAUTION). See below for the details. "DANGER" denotes that there is an imminent hazard which will cause serious personal injury or death during operation. "WARNING" denotes that there is a hazard which may cause serious personal injury or death during operation. "CAUTION" denotes that there is a hazard which may cause minor personal injury during operation. "CAUTION" without an exclamation symbol denotes that there is a hazard which may cause damage or failure of this system, facility, or devices. 1.2.2 Definitions of “Serious injury” and “Minor injury” “Serious injury” This term describes injuries such as loss of eyesight, wound, burns, frostbite, electric shock, fracture, and toxication that leaves aftereffects which may require prolonged treatment and hospitalization. “Minor injury” This term describes injuries that do not require prolonged treatment or hospitalization (injuries other than “serious injuries” described above). 1.2 Danger, Warning and Caution 1-2 HRG001-A HRG002-A HRG005-A st 1 edition : Dec. 2003 1 1.2.3 HRX-OM-H043 Safety Instructions Symbols This manual provides the following symbols in addition to “Danger”, “Warning”, and “Caution” to present the warning details in easy-to-understand manner. Symbol of electrical hazard This symbol warns you of possible risk of electrical shock. Symbol of heat hazard This symbol warns you of potential burns. Symbol of rotating shaft hazard This symbol warns you of possible risk caused by a rotating object. Symbol of “Don’ts” This symbol denotes the items that must not be attempted. Symbol of “Dos” This symbol denotes the “obligation” items which you must follow in operation of this unit. HRG001-A HRG002-A HRG005-A st 1 edition :Dec. 2003 1.2 Danger, Warning and Caution 1-3 HRX-OM-H043 1 Safety Instructions 1.3 Hazard Warning Label The hazard warning labels indicate where potential hazards are present during unit operation and maintenance. The hazard warning labels are in appropriate sizes and colors. They contain symbols in addition to the descriptions of warnings. 1.3.1 Classification of risks High voltage hazards The unit is operated at high voltage and may cause an electrical shock. The attached label contains the symbol . Do not operate the unit without cover panel mounted. The unit contains the power supply carrying high voltage inside that is isolated with the cover panel. Unit operation without the cover panel allows the high votage to apply outside and cause injuries. Only trained personnel are allowed to work around the power supply. High temperature hazards The unit reaches high temperature during operation and may cause burns when an operator comes in contact. The attached label contains the symbol . This symbol indicates the presence of a section where temperature reaches high and the operator sustains burns when coming in contact. Even after the power is turned off, residual heat may still cause burns. The work must not be started until the section drops to sufficiently low temperature. Rotating object hazards The unit includes several parts that rotate during operation and may cause the operator to get the finger caught in these parts. The attached label contains the symbol . The unit includes several parts which rotate during operation, and the operator who comes in contact may get injured. Even if that part seems to stop rotating, avoid touching it because the condition may be temporary and the rotation may restart. 1.3 Hazard Warning Label 1-4 HRG001-A HRG002-A HRG005-A st 1 edition : Dec. 2003 1 1.3.2 HRX-OM-H043 Safety Instructions Type of hazard warning labels Do not remove or deface the warning labels. Read the contents of the hazard warning labels with care to keep them in mind. Warning label on the front panel Fig. 1-1 Warning label on the front panel Warning label for high voltage Fig. 1-2 Warning label for high voltage HRG001-A HRG002-A HRG005-A st 1 edition :Dec. 2003 1.3 Hazard Warning Label 1-5 HRX-OM-H043 1 Safety Instructions 1.3.3 Location of hazard warning label z Recognize where the hazard warning labels are attached. z The user is not allowed to reposition the labels. If the label is replaced due to being peeled off or worn out, keep the previous position. Warning label for high voltage Warning label on the front panel Front Fig. 1-3 Location of hazard warning label 1.4 Model label Check the model no. described on the label. Front Fig. 1-4 Location of model label 1.4 Model label 1-6 HRG001-A HRG002-A HRG005-A st 1 edition : Dec. 2003 1 HRX-OM-H043 Safety Instructions 1.5 Disposition of waste 1.5.1 Recovery of refrigerant and compressor oil The unit belongs to Class 1 in the “Fluorocarbon Recovery and Destruction Law” and uses freon type refrigerant (HFC) and compressor oil. When these fluids need to be recovered, read the instructions below and ensure thorough understanding of them. If you have any questions, contact the local distributor or SMC’s sales branch. Only service personnel or qualified personnel are allowed to open the cover panel of the unit. Do not mix the compressor oil with domestic waste for disposition. Also, incineration is permitted only at an authorized incinerator. Comply with municipal ordinances or regulations to dispose of waste. The release of refrigerant to atmosphere is banned by law. If the refrigerant needs to be removed for repair of the unit, recover it with specific equipment and request a specialized waste disposal agency for disposal of the recovered refrigerant. A person must have proper license to perform refrigerant recovery. Only personnel with sufficient knowledge and experiences with the unit and associated equipment are allowed to recover refrigerant and compressor oil. The person must have proper license to perform refrigerant recovery. Remarks The type and amount of used freon can be found on the label. 1.5.2 Disposal of unit If the unit needs to be discarded, be sure to follow local laws and regulations on disposing of industrial waste. HRG001-A HRG002-A HRG005-A st 1 edition :Dec. 2003 1.5 Disposition of waste 1-7 HRX-OM-H043 1 Safety Instructions 1.5 Disposition of waste 1-8 HRG001-A HRG002-A HRG005-A st 1 edition : Dec. 2003 2 HRX-OM-H043 Descriptions of Components 2. Descriptions of Components 2.1 Appearance of unit 2.1.1 HRG001-A / HRG002-A Top Left Back Front Fig. 2-1 2.1.2 Right Appearance of unit(HRG001-A / HRG002-A) HRG005-A Top Left Back Front Fig. 2-2 HRG001-A HRG002-A HRG005-A st 1 edition :Dec. 2003 Right Appearance of unit(HRG005-A) 2.1 Appearance of unit 2-1 HRX-OM-H043 2 Descriptions of Components 2.2 Descriptions and functions of components 2.2.1 HRG001-A / HRG002-A Tank lid Power cable access (Cable Grip) Signal cable access (Cable Grip) Level indicator Electrical unit Top Control panel Circulating fluid OUT Rc1/2 Bypass valve Circulating fluid RETURN Rc1/2 Port for overflow Rc1/2 Air vent OUT Tank drain port Rc1/2 (plugged) Left Air vent OUT Front Air vent IN Right 4-φ13 (For anchor bolt) Fig. 2-3 Piping connection port(HRG001-A / HRG002-A) 2.2 Descriptions and functions of components 2-2 HRG001-A HRG002-A HRG005-A st 1 edition : Dec. 2003 2 2.2.2 HRX-OM-H043 Descriptions of Components HRG005-A Tank lid Power cable access (Cable Grip) Eye bolt M12 Level indicator Electrical unit Top Control panel Signal cable entry (Cable Grip) Circulating fluid RETURN Rc1/2 Circulating fluid OUT Rc1/2 Bypass valve Air vent OUT Port for overflow Rc1/2 Air vent IN Left Front 4-φ13 (for anchor bolt) Right Tank drain port Rc1/2 (plugged) Fig. 2-4 Piping connection port(HRG005-A) HRG001-A HRG002-A HRG005-A st 1 edition :Dec. 2003 2.2 Descriptions and functions of components 2-3 HRX-OM-H043 2 Descriptions of Components 2.2.3 Control panel The control panel is common to all models. Fig. 2-5 Control panel Table 2-1 Control panel No. Name 1 Digital display, PV / SV 2 3 4 5 6 7 8 9 10 [POWER] LED [RUN] LED [PUMP] LED [ALARM] LED [ON] switch [OFF] switch [MODE] key [DOWN] key [UP] key 2.2 Descriptions and functions of components 2-4 Function PV Indicates actual temperature of a circulating fluid SV Indicates set temperature of a circulating fluid Lights up when the power is supplied. Lights up when the [ON] switch is pressed. Lights up when an alarm arises. This is used to run the unit. This is used to stop the unit. This is used to switch the screens between PV and SV. This is used to decrease set temperature. This is used to increase set temperature. HRG001-A HRG002-A HRG005-A st 1 edition : Dec. 2003 3 HRX-OM-H043 Transport and Installation 3. Transport and Installation The unit must be handled in correct manner. Exercise caution to assure personnel safety during the installation, operation, maintenance, and inspection of the unit. Only personnel with sufficient knowledge and experiences with the unit and system are allowed to transport, install and conduct maintenance possibly exposed to dangerous situations. 3.1 Transport The unit is heavy and poses potential danger at transportation. To prevent damage to the unit, be sure to follow the instructions below when transporting the unit. If the forklift is used for transporting, ensure that the fork is inserted in a place as specified in Fig. 3-1 “Fork insertion position and unit lifting ”. If eyebolts are used for lifting, ensure the unit is held at four points. Keep each eyebolt at an angle from 45 to 60 degrees with repect to the postion of the center of gravity when lifting the unit. Never set the unit on its side. The refrigerant oil will drain into refrigerant piping from the compressor, reducing its amount in the compressor. It results in a compressor failure. Drain the residual fluid from piping as much as possible to prevent spill. If the forklift is used for transporting the unit, be sure to prevent the fork from contacting the cover panel or pipe connection ports. HRG001-A HRG002-A HRG005-A st 1 edition :Dec. 2003 3.1 Transport 3-1 HRX-OM-H043 3 Transport and Installation HRG001-A/HRG002-A Fork insertion position Fork insertion position Fork insertion position Fork insertion position Lifting position HRG005-A Approx. 60deg. Approx. 60deg. Fork insertion position Fork insertion position Fork insertion position Fork insertion position Fig. 3-1 Fork insertion position and unit lifting 3.1 Transport 3-2 HRG001-A HRG002-A HRG005-A st 1 edition : Dec. 2003 3 HRX-OM-H043 Transport and Installation 3.2 Installation Do not install the unit in a place possibly exposed to flammable gas. Ignition may occur if leaked gas is collected around the system. This unit is NOT designed for outside use. The unit exposed to moisture may develop a short circuit which can result in an electrical shock, fire and failure in the unit. Install the unit on a flat and level floor which can support the weight of the unit. Take measure to prevent the unit from tipping over. Improper setup may cause water leakage from the unit and personal injury. Keep ambient temperature of the unit between 5 and 40°C. Unit operation at below 5°C may lead to failure in the compressor. Operation at above 40°C will reduce effectiveness of the condenser and trigger the safety device which brings the unit to a stop. 3.2.1 Installation Conditions Do not use or store the unit in the following environments. Potential unit malfunction and damage may occur if disregarded. z Environment that is exposed to water vapor, salt water or oil mist z Environment that is exposed to dust or powdery materials z Environment that is exposed to corrosive gas, flammable gas or solvent z Environment that is exposed to direct sun light or radiant heat z Environment where ambient temperature is out of the specified range between 5°C to 40°C z Environment that is subjected to abrupt changes in temprature z z Environment that is subjected to strong electromagnetic noise(incl. strong electrical field, strong magnetic field, or surge voltage) Environment that generates static electricity, or condition in which static electricity discharges to the unit z Environment that generates strong high frequencies z Environment at high altitudes of over 1000m z Condition which allows strong vibrations and impacts to transmit to the unit z Condition with external force or load to deform the unit z Condition with an insufficient maintenance space as required z Condition with an insufficient maintenance space as required HRG001-A HRG002-A HRG005-A st 1 edition :Dec. 2003 3.2 Installation 3-3 HRX-OM-H043 3 Transport and Installation 3.2.2 Installation z Keep the unit away from vibration. Install the unit on a flat and stable surface. z Refer to “7.2 Outline dimensions” for the dimensions of the unit. 3.2.3 Electrical wiring z Do not modify the electrical wiring. Incorrect wiring can cause an electrical shock and fire. Failure to do so will void any warranty. z The set value of the safety device must not be changed. Changing the set value can cause system failure and fire. z Only qualified personnel are allowed to install wiring. z Be sure to disconnect the power for safety. Wiring installation with the unit energized is strictly prohibitted. z Use the specified cables. Properly apply strain relief to prevent an external force from being exerted on the terminals. Poor or loose connection can cause electrical shock, heat spots, or fire. z Supply the power to the unit from a reliable power source (without surge or sag voltage). z Be sure to use a GFCI breaker to prevent an electrical shock and burnt compressor motor. The breaker with adequate capacity of current leakage and load should be selected in accordance with “7.1 Specification list”. z Ensure that the power supply meets the specification of the unit. z Always establish a ground for safety. z Do not connect the ground to a water line, gas pipe or lighting conductor. z Do not branch off the wiring to make multiple circuits. Potential hot spots or fire may occur if disregarded. Power supply cable and GFCI breaker Select a cable for power supply and GFCI breaker corresponding to the model no. provided in the following table. Table 3-1 Cable for power supply and current leakage Item HRG001-A HRG002-A Power Size 4-core 3.5mm2 supply Round compressive 3.5-4S cable terminal size Size 6-core 0.75 mm2 Signal cable 1.25Y-3 Fork terminal size ※ Capacity of GFCI breaker 5A 10A ※Use the breaker with current sensitivity of 30mA at minimum. 3.2 Installation 3-4 HRG005-A 4-core 5.5mm2 5.5-4S 20A HRG001-A HRG002-A HRG005-A st 1 edition : Dec. 2003 3 HRX-OM-H043 Transport and Installation How to conduct wiring 1. Undo the screws (6 pcs.) and take off the front panel. Screw Screw Front panel Front Fig. 3-2 Removal of front panel 2. Connect the power supply cable and signal cable as shown in the figure. Power supply cable Signal cable Signal cable entry Front Power supply cable entry Fig. 3-3 Electrical wiring (HRG001-A / HRG002-A) Power supply cable Front Signal cable Signal cable entry Power supply cable entry Fig. 3-4 Electrical wiring (HRG005-A) HRG001-A HRG002-A HRG005-A st 1 edition :Dec. 2003 3.2 Installation 3-5 HRX-OM-H043 3 Transport and Installation Electrical wiring diagram z Prepare cables for the power supply and signal lines separately . z Maintain polarities (+, -) of DC24V when connecting the signal cable for transmitting start/stop command (remote operation). z Refer to “7.3 Electrical circuit diagram” for the electrical circuit of the unit. • HRG001-A / HRG002-A User’s preparation Thermo cooler ELB/Current leakage breaker Power supply input Power supply cable Electrical circuit FG(Frame ground) Remote operation signal input DC +24V input DC 0V input Error detected stop signal output, relay contact (normally open, closed for error) Operation signal output, relay contact (normally close, opened for error) Remote operation input circuit Signal cable Error detected stop signal output circuit Operation signal output circuit I/O board Fig. 3-5 Installation (electrical wiring) • HRG005-A User’s preparation Power supply box ELB/Current leakage breaker Power supply input Power supply cable Electrical circuit FG(Frame ground) Remote operation signal input DC +24V input DC 0V input Error detected stop signal output, relay contact (normally open, closed for error) Operation signal output, relay contact (normally close, opened for error) Remote operation input circuit Signal cable Error detected stop signal output circuit Operation signal output circuit I/O board Fig. 3-6 Installation (electrical wiring) 3.2 Installation 3-6 HRG001-A HRG002-A HRG005-A st 1 edition : Dec. 2003 3 3.2.4 HRX-OM-H043 Transport and Installation Piping z Install piping properly. Improper installation may cause leaks. z Keep facility water pressure below 0.5MPa. z Make sure the locations of IN and OUT ports for circulating fluid supply. The reverse connection inhibits proper operation of the unit. z Make sure no entry of dust and foreign materials into the water circuit during piping installation. z Hold the piping connected port with a pipe wrench when tightening the pipe. Excessive force will damage the port and cause leaks if disregarded. Pipe diameter The pipe diameters are common to all models. Table 3-2 Pipe diameter Pipe Recirculating fluid OUT Recirculating fluid return Port for overflow Port for drain in tank Diameter Rc1/2 Rc1/2 Rc1/2 Rc1/2 How to install piping 1. Hold the piping connected port with a specific wrench and tighten the pipe. Connected port 29.4N・m or less Fig. 3-7 Tightening of pipe Remarks Install a valve at the drain port to facilitate the draining of the circulating fluid from the tank. (The valve needs to be prepared separately.) HRG001-A HRG002-A HRG005-A st 1 edition :Dec. 2003 3.2 Installation 3-7 HRX-OM-H043 3 Transport and Installation Recommended piping installation Circulating fluid OUT Load device Circulating fluid return Tank drain port Drain pit Port for overflow Fig. 3-8 Recommended piping installation No. 1 2 3 4 5 3.2.5 Name Valve Y-shaped strainer Relieving valve Pressure gauge Flow meter Size Rc1/2 Rc1/2 Rc1/2, set from 0 to 0.5 MPa 0 to 1.0 MPa 0 to 50 L/min Supply of circulating fluid 1.Open the tank lid and supply the circulating fluid until the fluid reaches the range specified on the level indicator. Keep the fluid level in the tank between “HIGH” and “LOW”. If the fluid is out of the range, the circulating fluid may overflow that results in a ground falut. HIGH Opening for level check Opening for level check HIGH Level range Level range LOW LOW HRG001-A & HRG002-A HRG005-A Fig. 3-9 Level indicator 3.2 Installation 3-8 HRG001-A HRG002-A HRG005-A st 1 edition : Dec. 2003 3 3.2.6 HRX-OM-H043 Transport and Installation Reinstallation of unit If the unit is relocated, only personnel with knowledge of the unit and associated equipment are allowed to perform unit reinstallation. Precautions described below must always be followed. When the unit is transferred to and reinstalled in a different place after operation at the original place (including trial run), perform transporting and installation of the unit according to the procedures described below and in Chapter 3. Disconnection of power supply cable Be sure to cut off the power supply when disconnecting the power supply cable. z Only qualified personnel are allowed to install wiring. z Be sure to cut off the power supply for safety. Wiring with the unit energized is strictly prohibitted. HRG001-A HRG002-A HRG005-A st 1 edition :Dec. 2003 3.2 Installation 3-9 HRX-OM-H043 3 Transport and Installation 3.2 Installation 3-10 HRG001-A HRG002-A HRG005-A st 1 edition : Dec. 2003 4 HRX-OM-H043 Startup and Shutdown 4. Startup and Shutdown Personnel with adequate knowledge and experiences of this product and peripheral devices shall be in charge of starting up and shutting down the unit. 4.1 Pre-check Check the following items before starting up the unit. 4.1.1 Installation condition z Make sure the unit is installed horizontally. z Do not put any heavy object on the unit or apply excess force by piping. 4.1.2 Connection of cable Check that the power cable, ground and I/O signal cables are correctly connected. 4.1.3 Piping for circulating fluid Check the I/O piping of the circulating fluid is installed correctly. 4.1.4 Level indicator(for level in the tank) Check the fluid level is within the specified range. HRG001-A HRG002-A HRG005-A st 1 edition :Dec. 2003 4.1 Pre-check 4-1 HRX-OM-H043 4 Startup and Shutdown 4.2 Preparation for startup 4.2.1 Power supply Supply the power. The following conditions are observed on the control panel upon power-ON. z The [POWER] LED lights up. z The digital display PV lights up and displays temperature of the circulating fluid. z The [ALARM] LED lights up and goes out in 5 sec. [POWER]LED [ALARM]LED Digital display PV Fig. 4-1 Power supply 4.2.2 Setting of circulating fluid temperature Press the [UP] and [DOWN] keys to set a desired temperature in the digital display SV. Digital display SV [DOWN]key Fig. 4-2 Setting of circulating fluid temperature z Note: Circulating fluid setting temp.range is 5 to 35°C. [UP]key 4.2 Preparation for startup 4-2 HRG001-A HRG002-A HRG005-A st 1 edition : Dec. 2003 4 4.2.3 HRX-OM-H043 Startup and Shutdown Additional water supply [TS] switch (pump manual operation switch): HRG005-A only HRG005-A has the [TS] switch (pump manual operation switch) to purge air from the circulating fluid circuit at initial startup. Remove the front panel, and purge air according to the procedures given below. [TS] switch Front Fig. 4-3 [TS]switch(ポンプ単独運転 switch) 1. Press the [TS] switch for several seconds, monitoring the fluid level gauge. Air is purged from the pipe, and the fluid level is lowered. 2. Supply the circulating fluid again according to section 3.2.5. If leakage occurs due to faulty piping including an opened fitting of eternal piping, stop manual operation of the pump and fix the leak. HRG001-A HRG002-A HRG005-A st 1 edition :Dec. 2003 4.2 Preparation for startup 4-3 HRX-OM-H043 4 Startup and Shutdown 4.3 Unit Startup and Shutdown 4.3.1 1. Starting the unit Press the [ON] switch on the control panel. The unit starts operating and regulates the circulating fluid temperature. The [RUN] LED and [PUMP] LED on the control panel come on. [RUN]LED [PUMP]LED [ON]switch Fig. 4-4 Starting the unit 4.3.2 1. Stopping the unit Press the [OFF] switch on the control panel. The unit stops. The [RUN] LED and [PUMP] LED on the control panel go out. [RUN]LED [PUMP]LED [OFF]switch Fig. 4-5 Stopping the unit 4.3 Unit Startup and Shutdown 4-4 HRG001-A HRG002-A HRG005-A st 1 edition : Dec. 2003 4 HRX-OM-H043 Startup and Shutdown 4.4 Check at startup Check the following items at startup of the unit. When any abnormality is found, press the [OFF] switch immediately to stop the unit and turn the power breaker off. z No leak from circulating fluid piping z No circulating fluid flowing out of the tank drain port z Circulating fluid pressure within the specified range Bypass valve Normally, the bypass valve is fully opened. If the unit is started up with the valve fully closed, water supply may reach abnormal high pressure depending on external piping conditions. Be sure to keep the bypass valve fully opened for initial startup of the unit installed. Adjust the bypass valve to obtain required pressure and flow rate by checking on the external pressure gauge and flow meter that can be prepared by customer or mounted on external piping. Bypass valve Right Fig. 4-5 Bypass valve (HRG001-A / HRG002-A) HRG001-A HRG002-A HRG005-A st 1 edition :Dec. 2003 Right Fig. 4-6 Bypass valve (HRG005-A) 4.4 Check at startup 4-5 HRX-OM-H043 4 Startup and Shutdown 4.4 Check at startup 4-6 HRG001-A HRG002-A HRG005-A st 1 edition : Dec. 2003 5 HRX-OM-H043 Error Message and Troubleshooting 5. Error Message and Troubleshooting 5.1 Error Message This product stops when an error is detected. Table 5-1 shows the LED conditions (ON/OFF) and signal output in the event of the error. [POWER]LED [RUN]LED [ALARM]LED Fig. 5-1 Control panel Table 5-1 Error message Open contact Open contact Open contact Error stop signal output Closed contact Open contact Open contact Red ○ Open contact Open contact ● Red ○ Green○ ● Red ○ Stopped Green○ ● Red ○ Stopped Green○ ● Red ○ Open contact Open contact Open contact Open contact Open contact Open contact Open contact Open contact Setting range Unit status Power error - Start-up failure Alarm LED (●: Off, ○: On) Operation signal output ALARM POWER RUN Stopped ● ● ● - Stopped Green○ ● Red ○ Reverse of pump and compressor - Stopped Green○ ● Red ○ Tank water level drop Lower limit of water level in the tank Stopped Green○ ● Pump overload - Stopped Green○ Compressor overload - Stopped Min.40°C Min.40°C High temp. of supplied water Excess temp. rise in fan motor* * Only HRG005-A HRG001-A HRG002-A HRG005-A st 1 edition :Dec. 2003 5.1 Error Message 5-1 HRX-OM-H043 5 Error Message and Troubleshooting 5.2 Troubleshooting Table 5-2 Troubleshooting Alarm Unit status Power error The [POWER] LED is not turned on. Startup failure The [RUN] LED remains off even with the press of the [ON] switch Reverse of pump and compressor Cause Power is not supplied. A breaker is tripped. Low voltage Failure in the [POWER] LED One of the three-phase power is interrupted. A voltage sag occurred. Failure in the [RUN] LED Failure in the [ON] switch Incorrect phase sequence of Reverse phase power wiring relay triggered. Tank water level drop Level switch contact is opened. Pump overload Pump thermal overload switch has been tripped. Inadequate water in the tank (natural evaporation) Power voltage sag Abnormal rise in circullating fluid pressure Abnormal failure of pump Power voltage sag Compressor overload Compressor thermal overload switch has been tripped. Abnormal heat dissipation capability of condensor. Improper rated cooling capability Refrigerant leak Abnormal failure in the compressor Failure in the electromagnetic switch Rise in ambient temperature High temp. of circulating fluid Temp. rise in fan motor* The contact of temperature controller EV1 is opened. The contact of the thermostat for fan motor is open. Remedies Supply the power. Fix a short or ground fault. Supply a rated voltage. Ask for service. Normal according to product spec. Supply three-phase power. Ask for service. Ask for service. Normal according to product spec. Rewire the power cable for two of three phases. Wiring should be performed by a qualified person. Normal according to product spec. Circulating water is low in amount. Supply the circulating water. Normal according to product spec. Boost up the capacity of power breaker. Wiring should be performed by a qualified person. Adjust the opening of the manual relief valve. Ask for service. Change the pump. Ask for service. Normal according to product spec. Boost up the capacity of power breaker. Wiring should be performed by a qualified person. Normal according to product spec. Improve ambient conditions to provide ventilation and exhaust heat. Failed condensing fan Normal according to product spec. Reduce a heating value output from user’s unit. How to reset Manual reset Auto reset Auto reset Auto reset Manual reset Manual reset Ask for service to get the refrigerant gas charged and the compressor and electromagnetic switch replaced. Improve ambient conditions. Avoid installing it at a place exposed to direct sunlight or radiant heat. Normal according to product spec. Improper rated cooling capability Reduce a heating value output from user’s unit. Refrigerant leak Failure in the refrigerant solenoid Ask for service to get the valve refrigerant gas charged and the Failure in the compressor compressor and electromagnetic Other abnormalities in the switch replaced. refrigeration circuit Failure in the temperature controller Rise in ambient temperature Improve ambient conditions. Avoid installing it at a place exposed to direct sunlight or radiant heat. Improper rated cooling capability Reduce a heating value output from user’s unit. Replace the fan motor. Failure in the fan motor Ask for service. Auto reset Auto reset *Only apply to model HRG005-A 5.2 Troubleshooting 5-2 HRG001-A HRG002-A HRG005-A st 1 edition : Dec. 2003 6 HRX-OM-H043 Unit Maintenance 6. Unit Maintenance 6.1 Control of water quality The circulating fluid used in this unit is fresh water (tap water). This unit may be damaged when unpermitted fluids are used. Potential fluid leak may occur if disregarded, which results in electric shock and ground fault. ONLY use fresh water (tap water) which satisfies water quality standards as shown in the table below. Table 6-1 Water quality standards for fresh water (tap water) Substances Standard Reference pH (25°C) Electrical conductivity (25°C) (µs/cm) Chloride ion (mgCl-/L) Sulfuric acid ion (mgSO42-/L) Acid consumption (pH4.8) (mgCaCO3/L) Total hardness (mgCaCO3/L) Calcium hardness (mgCaCO3/L) Ion silica (mgSiO2/L) Iron (mgFe/L) Copper (mgCu/L) Sulfide ion (mgS2-/L) Ammonium ion (mgNH4+/L) Residual chlorine (mgCl/L) Free carbon dioxide (mgCO2/L) Cooling water system/ Circulating fluid 6.8 to 8.0 1 to 400 50 and below 50 and below 50 and below 70 and below 50 and below 30 and below 1.0 and below 1.0 and below Not detected 1.0 and below 0.3 and below 4.0 and below *Excerpt from the Refrigeration and Air Conditioning Equipment Water Quality Guideline JRA-GL-02-1994 If the periodic inspection finds a nonconforming substance in the facility water, wash the tank and the cirulating circuit, and replace the water in the tank. Water will evaporate, and impurities will build up. Even if no abnormal event occurs, it is recommended to replace the water in the tank once every three months. Refer to section "6.2 Inspection and Cleaning" for the periodic inspection. HRG001-A HRG002-A HRG005-A st 1 edition :Dec. 2003 6.1 Control of water quality 6-1 HRX-OM-H043 6 Unit Maintenance 6.2 Inspection and cleaning Do not operate the switches, etc. with wet hands and do not touch any electrical components such as a power supply plug. It may cause an electric shock if disregarded. Keep this unit from water. Do not wash the unit with water. It may cause an electric shock and fire if disregarded. Do not touch the fin directly during cleaning of the condenser. It may cause personal injury if disregarded. Cut off the power supply of the unit before performing cleaning, maintenance and inspection. It may cause an electric shock, injury or burn if disregarded. Always mount the panel back onto the unit after removing the panel for inspection or cleaning. Failure to close or re-attach the panel may cause personal injury or electric shock during unit operation. 6.2 Inspection and cleaning 6-2 HRG001-A HRG002-A HRG005-A st 1 edition : Dec. 2003 6 6.2.1 HRX-OM-H043 Unit Maintenance Daily inspection Check the items listed below before, during, and after operation of this unit. If any abnormal event is detected, stop operation and turn off the main breaker. Be sure to lock out and tag out the unit before asking for service. z The circulating fluid should fall within the specified level. When it is out of the range, replenish or drain excess circulating fluid to maintain a proper level. (Be sure to stop the unit before replenishing the circulating fluid.) z The characters and numbers on the liquid crystal display of the control display panel should be clear. z There should be no leak from circulating fluid piping. z Water supply pressure of the circulating fluid should be within the specified range. (Discharge pressure of the circulating fluid should be lower than the proof pressure of user’s unit.) z There should be no abnormal sound or abnormal vibration from this unit. z There should be no foul smell or smoke from this unit. HRG001-A HRG002-A HRG005-A st 1 edition :Dec. 2003 6.2 Inspection and cleaning 6-3 HRX-OM-H043 6 Unit Maintenance 6.2.2 Monthly inspection Cleaning of the filter for the air-cooled condenser (optional accessory) Attach a filter screen when operating this unit in a place that the fin of the air-cooled condenser becomes dirty and clogged. The filter screen is an optional accessory. z Remove the filter and eliminate dirt with a vaccum cleaner. z Detach the filter and wash it with detergent if it is dirty. Place it back when it is dried. z Brush Vacuum cleaner Wash it with water and apply gentle brush motion. Fig. 6-1 Cleaning of the filter for the air-cooled condenser. (Optional accessory) Inspection of the tank Check the following items. Replenish or replace fresh water (tap water), or clean it when an abnormal event is found. z Foreign materials adhere to the inner wall of the tank. z Slime is found on the inner wall of the tank. z Foreign materials float on the surface of fulid in the tank. z There is scale deposited in the tank. z It has a foul odor. z The water has been discolored. 6.2 Inspection and cleaning 6-4 HRG001-A HRG002-A HRG005-A st 1 edition : Dec. 2003 6 6.2.3 HRX-OM-H043 Unit Maintenance Biannual inspection Cleaning of the air-cooled condenser The safety device may get activated to stop the operation when the fin is clogged with dust. z Clean the fin with a soft brush or an air gun with caution not to damage the fin. Cleaning of the condenser with a brush Cleaning of the condenser with an air gun Fig. 6-2 Cleaning of air-cooled condenser Check for leak from the pump mechanical sealing Remove the panel and check for leak from the pump mechanical sealing. When a leak is found, it is necessary to replace the mechanical sealing. Contact the local distributor or SMC’s sales branch. I m p o r t a n t z Leak from the mechanical sealing Leakage from the mechanical sealing occurs in structure. Although JIS defines leakage for 3cc/hr or less (reference value), 0.3cc/hr or more is our leakage standard suggested for the replacement of the mechanical sealing. A recommended replacement cycle of the mechanical sealing is 6000 to 8000 hours a year (usually). HRG001-A HRG002-A HRG005-A st 1 edition :Dec. 2003 6.2 Inspection and cleaning 6-5 HRX-OM-H043 6 Unit Maintenance 6.3 Storage Follow the procedures below for long-term storage of the unit. 1. Turn off the main power breaker. 2. Fully open the drain valve and drain the water from the tank. 3. Remove the drain plug of the circulating pump and drain the water from the pump. 4. Cover the unit with a plastic sheet for storage after draining is completed. 6.4 Consumables Replace the following parts in response to the level of wearing out at inspection. Table 6-2 Biannual inspection Part number HRG-S0003 Part Pump mechanical sealing Qty. 1 set Remarks For HRG005 * It is not required for HRG001 and HRG002. 6.3 Storage 6-6 HRG001-A HRG002-A HRG005-A st 1 edition : Dec. 2003 HRX-OM-H043 7 Documents 7. Documents 7.1 Specifications list Table 7-1 Specifications list Item HRG001-A HRG002-A Rated ambient humid. range Installation/ Op. Environment HRG005-A 32°C 45-75%RH(No condensation) Operating fluid Circulating fluid/fresh water (tap water) Rated capacity of tank 10L Power sup. voltage 20L 3-phase Input Recommended leak breaker capacity 5A AC200/200-220V(50/60 Hz) 10A 20A Breaker sensitivity current 30mA Start/stop instruction signal (Remote op. signal) Rated temp. & accuracy of circulating fluid Remote operation starts at DC24V and 8 mA are applied and stops at DC0V. 20±1.0°C and 0.5°C(Temp. setting range 5-35°C) Rated cooling capacity 0.9/1.1 kW(50/60 Hz) Output Pumping capacity Signal output Op. signal Emergency. Stop signal 1.9/2.3 kW(50/60 Hz) 4.5/4.8 kW(50/60 Hz) 29/37 L/min(Head 10 m) 33/42 L/min(Head 10 m) Relay contact (Contact cap. AC250V, 1A, resistance load. Contact closes during operation, and contact opens during stop and during power shutdown.) Relay contact (Contact cap. AC250V, 1A, resistance load. Contact closes while alarm light remains OFF and during power shutdown, and contact opens while alarm light remains ON.) Unit stop function for low tank level (with tank level switch) Protective function ( for equipment ) Pump/compressor reverse rotation detection (with phase relay) Pump reverse rotation detection (with phase relay) Unit stop function for pump/compressor overload (with over current relay) Emergency stop Unit stop function for abnormal fan motor temperature rise (Temp. fuse is built into fan motor) Unit stop function for abnormal fan motor temperature rise (Thermostat is built in fan motor.) Unit stop function for abnormal circulating fluid temperature rise (Set temp. of the temp. controller: 40°C) Others Protection against excessive temp. increase of compressor(OLP), Protection against pressure increase of circulating fluid (With manual valve), Leak protection (With drain pan) Outside panel SGCC(Munsell 10Y8/0.5 Urban white) Material/Substance Control panel SGCC(DIC183 Blue) Base SECC(Paint Munsell 10Y6/0.5 Urban gray) Wetted part SUS (connections such as inlet and outlet), BC (hose fitting, tube fitting), PVC (piping hose for internal water feeding), PPE (pump casing, impeller), PE (tank) SUS (pump impeller, connections such as Inlet and outlet), BC (pump casing, hose fitting), PVC (piping hose for internal water feeding), PE (tank) Internal piping for refrigerant C1220T Operating refrigerant HFC-407C Accessories No accessories Eye bolt M12×4 pcs. (Please prepare a power supply, signal cable and connection terminal under your responsibility.) Weight HRG001-A HRG002-A HRG005-A st 1 edition :Dec. 2003 Approx. 65kg Approx. 70kg Approx. 117kg 7.1 Specifications list 7-1 HRX-OM-H043 7 Documents 7.2 Outline dimensions HRG001-A and HRG002-A 400 7.2.1 500 950 Top view 300 250 Left side Front view Right side Fig. 7-1 Outline dimensions (HRG001-A / HRG002-A) HRG005-A 550 7.2.2 595 1150 Top view 328 536 Left side Front view Right side Fig. 7-2 Outline dimensions (HRG005-A) 7.2 Outline dimensions 7-2 HRG001-A HRG002-A HRG005-A st 1 edition : Dec. 2003 HRX-OM-H043 7 Documents 7.3 Electric circuit diagram 7.3.1 HRG001-A and HRG002-A Fig. 7-3 Electric circuit diagram (HRG001-A / HRG002-A) HRG001-A HRG002-A HRG005-A st 1 edition :Dec. 2003 7.3 Electric circuit diagram 7-3 HRX-OM-H043 7 Documents 7.3.2 HRG005-A Fig. 7-4 Electric circuit diagram (HRG005-A) 7.3 Electric circuit diagram 7-4 HRG001-A HRG002-A HRG005-A st 1 edition : Dec. 2003 HRX-OM-H043 7 Documents 7.4 Flow chart 7.4.1 HRG001-A and HRG002-A PS CD FM Draft SV TI R Circulating fluid feeding port Circulating fluid return port RV CRV Refrigeration circuit Draft Over flow port R Water feed circuit Tank drain port Recirculating fluid flow Sym bol CM CD PS FM D EV A R Name Compressor Air-cooled condenser Pressure switch for fan Fan Motor Refrigerant dryer Evaporator (Cooler) Accumulator Capillary tube Capacity regulating CRV valve SV Solenoid valve T Tank LS Level switch LI Level indicator PM Pump TI Temperature sensor RV Regulating valve Refrigerant flow Fig. 7-5 Flow chart (HRG001-A and HRG002-A) 7.4.2 HRG005-A Over flow port PS1 R Refrigeration circuit R CD Draft FM Draft SV R TI Circulating fluid feeding port Circulating fluid return port Tank drain port Water feed circuit RV Sym bol CM CD PS1 FM D EV A R SV PS2 T LS LI PM TI RV Name Compressor Air-cooled condenser Pressure switch for fan Fan motor Refrigerant dryer Evaporator(Cooler) Accumulator Capillary tube Solenoid valve Low pressure switch Tank Level switch Level indicator Pump Temperature switch Regulating valve Circulating fluid flow Refrigerant flow Fig. 7-6 Flow chart (HRG005-A) HRG001-A HRG002-A HRG005-A st 1 edition :Dec. 2003 7.4 Flow chart 7-5